Production method of concrete aerogel composite thermal insulation wallboard

Abstract

The invention discloses a production method of a concrete aerogel composite thermal-insulation wallboard, and belongs to the technical field of thermal-insulation material products.According to the scheme, aerogel particles are modified through a silane coupling agent, the compatibility of aerogel and epoxy resin is effectively improved, the aerogel is evenly dispersed in a thermal-insulation core layer in cooperation with a vacuum defoaming technology, and the thermal-insulation performance of the thermal-insulation core layer is improved; the heat conductivity coefficient of the wallboard is reduced to 0.025 W / (mK) or below, the heat preservation performance is remarkably improved, a composite forming structure of concrete slurry, glass fiber mesh cloth, a heat preservation core layer and concrete slurry is adopted, the glass fiber mesh cloth enhances the bonding strength of a concrete base material and the heat preservation core layer, the bonding strength is larger than or equal to 0.8 MPa, the stripping problem caused by long-term use is avoided, and the heat preservation performance is remarkably improved. Pretreatment, core layer preparation, composite forming, gradient curing and other procedures are integrated, the production process is simplified, the production period is shortened by 30% or above, meanwhile, the size error of a finished product is smaller than or equal to + / -0.5 mm through the mold precision control and vibration compaction technology, the product quality is improved, and the gradient curing technology effectively relieves temperature stress.

Description

Technical Field

[0001] This invention relates to the field of thermal insulation material production technology, and more specifically, to a method for producing concrete aerogel composite thermal insulation wall panels. Background Technology

[0002] Amid the global energy crisis, building energy conservation has become a core issue for sustainable development in various countries. According to statistics, building energy consumption accounts for more than 40% of global total energy consumption, with heat loss from building envelopes accounting for as much as 60%-70%. Traditional insulation materials such as polystyrene boards (EPS) and polyurethane (PU) have good insulation performance, but they also have problems such as flammability, poor durability, and construction pollution, making it difficult to meet the complex requirements of modern buildings for safety, environmental protection, and long life. Against this backdrop, inorganic insulation materials have gradually become a research hotspot due to their Class A fire resistance, environmental friendliness, and lifespan comparable to that of buildings.

[0003] Existing concrete insulation wall panels mostly use polystyrene boards, extruded polystyrene boards, etc. as the core insulation layer, which are formed by bonding or casting. These wall panels have limited insulation performance, with thermal conductivity generally higher than 0.03W / (m・K), making it difficult to meet the requirements of high-efficiency insulation. At the same time, the bonding strength between the insulation layer and the concrete substrate is low, and peeling and falling off are prone to occur after long-term use. Moreover, the production process is mostly carried out in steps, which is cumbersome, has low production efficiency, and poor dimensional accuracy of finished products. In addition, the traditional production method lacks effective control over the dispersion of aerogel, resulting in uneven distribution of aerogel in the composite layer, which affects the overall insulation effect and structural stability of the wall panel, and cannot achieve a synergistic improvement in insulation performance, mechanical strength and production efficiency. Summary of the Invention

[0004] 1. Technical problems to be solved To address the problems existing in the prior art, the present invention aims to provide a method for producing concrete aerogel composite thermal insulation wall panels, which can achieve uniform dispersion of aerogel in the composite layer, improve the thermal insulation performance and structural stability of the wall panels, simplify the production process, and improve production efficiency.

[0005] 2. Technical Solution To solve the above problems, the present invention adopts the following technical solution.

[0006] A method for producing a concrete aerogel composite thermal insulation wall panel includes the following steps: S1. Place the nano-silica aerogel particles into the modifier solution, stir and disperse at 30-40℃ for 20-30 minutes, filter, and dry at 80-100℃ to constant weight to obtain the modified aerogel. S2. Mix the modified aerogel, epoxy resin, and curing agent in a mass ratio of 1:3-5:0.8-1.2, pour the mixture into a mold, degas it under vacuum, and then cure it at 50-60℃ for 2-3 hours to form an aerogel insulation core layer. S3. Mix cement, aggregate, admixture, and water in a mass ratio of 1:2.5-3.5:0.02-0.05:0.4-0.5 and stir evenly to obtain concrete slurry; S4. First, pour the concrete slurry into the bottom layer of the composite mold, lay a layer of fiberglass mesh, then embed the cured aerogel insulation core layer into the middle of the composite mold, and then inject the concrete slurry into the upper layer of the composite mold. After vibration and compaction, smooth the surface. S5. Place the composite mold in the curing room and cure it for 4-6 hours at 20-25℃ and 80-90% humidity. Then, raise the temperature to 40-50℃ and 70-80% humidity and cure it for 12-16 hours. Finally, cool it down to room temperature and cure it naturally for 24-36 hours. Demold the mold to obtain the concrete aerogel composite insulation wall panel.

[0007] Furthermore, the modifier solution in S1 is a mixed solution prepared by silane coupling agent KH-550 and ethanol at a volume ratio of 1:15-20, and the liquid-solid ratio of the modifier solution to the nano silica aerogel particles is 5-8:1.

[0008] Furthermore, in S2, the vacuum degree of vacuum degassing is -0.08 to -0.1 MPa, the degassing time is 15-20 minutes, and the thickness of the aerogel insulation core layer is controlled at 20-40 mm.

[0009] Furthermore, in S3, the aggregate is composed of quartz sand with a particle size of 0.5-1mm and basalt crushed stone with a particle size of 2-5mm mixed at a mass ratio of 2:1, and the admixture is a polycarboxylate-based high-efficiency water-reducing agent.

[0010] Furthermore, in S4, the glass fiber mesh has a mesh count of 80-120, and its adhesion to the concrete slurry during laying is not less than 95%. The vibration compaction frequency is 50-60Hz, and the compaction time is 3-5 minutes.

[0011] Furthermore, in S4, the cavity size error of the composite mold is controlled within ±0.5mm, the thickness of the bottom layer of concrete slurry is 30-50mm, and the thickness of the top layer of concrete slurry is the same as that of the bottom layer.

[0012] Furthermore, in S5, the heating rate is controlled at 5-8℃ / hour and the cooling rate is controlled at 3-5℃ / hour to avoid sudden temperature changes that could cause the wall panel to crack.

[0013] Furthermore, the process also includes post-processing steps: the surface of the demolded wall panel is sanded to remove burrs and protrusions, and then a layer of penetrating waterproofing agent is sprayed onto the surface at a rate of 0.2-0.3 kg / m². After air drying, the panel is stored in the warehouse.

[0014] Furthermore, the curing agent in S2 is an amine-based curing agent. After the aerogel insulation core layer is cured, its compressive strength is tested, and the qualified standard is a compressive strength ≥ 1.5 MPa.

[0015] Furthermore, in S3, the concrete slurry is mixed using a twin-shaft screw mixer for 8-12 minutes at a speed of 300-400 r / min to ensure that the slurry is uniform and free of lumps.

[0016] 3. Beneficial Effects Compared with the prior art, the advantages of this invention are: This solution modifies aerogel particles with a silane coupling agent, effectively improving the compatibility between aerogel and epoxy resin. Combined with a vacuum degassing process, it achieves uniform dispersion of the aerogel in the insulation core layer, reducing the thermal conductivity of the wall panel to below 0.025 W / (m·K), significantly improving insulation performance. A composite molding structure of "concrete slurry - fiberglass mesh - insulation core layer - concrete slurry" is adopted. The fiberglass mesh enhances the bonding strength between the concrete substrate and the insulation core layer, achieving a bonding strength ≥0.8 MPa, preventing peeling issues over long-term use. The solution integrates pretreatment, core layer preparation, composite molding, and gradient curing processes, simplifying the production flow and shortening the production cycle by more than 30%. Furthermore, through precise mold control and vibration compaction, the finished product dimensional error is ≤±0.5 mm, improving product quality. The gradient curing process effectively alleviates temperature stress, and combined with post-treatment waterproof spraying, the wall panel's water absorption rate is ≤3%, and its compressive strength is ≥15 MPa, balancing insulation performance and structural stability, thus broadening its applicability. Attached Figure Description

[0017] Figure 1 A perspective view of the thermal insulation wall panel of the present invention.

[0018] Explanation of the labels in the diagram: 1. Composite mold; 2. Concrete slurry; 3. Fiberglass mesh; 4. Aerogel insulation core layer. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0020] In the description of this invention, it should be noted that the terms "upper," "lower," "inner," "outer," "top / bottom," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0021] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed," "equipped with," "sleeved / connected," "connected," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0022] Example: A method for producing a concrete aerogel composite thermal insulation wall panel includes the following steps: S1. Place the nano-silica aerogel particles into the modifier solution, stir and disperse at 30-40℃ for 20-30 minutes, filter, and dry at 80-100℃ to constant weight to obtain the modified aerogel. S2. Mix the modified aerogel, epoxy resin, and curing agent in a mass ratio of 1:3-5:0.8-1.2, pour the mixture into a mold, degas it under vacuum, and then cure it at 50-60℃ for 2-3 hours to form an aerogel insulation core layer. S3. Mix cement, aggregate, admixture, and water in a mass ratio of 1:2.5-3.5:0.02-0.05:0.4-0.5 and stir evenly to obtain concrete slurry; S4. First, pour the concrete slurry into the bottom layer of the composite mold, lay a layer of fiberglass mesh, then embed the cured aerogel insulation core layer into the middle of the composite mold, and then inject the concrete slurry into the upper layer of the composite mold. After vibration and compaction, smooth the surface. S5. Place the composite mold in the curing room and cure it for 4-6 hours at 20-25℃ and 80-90% humidity. Then, raise the temperature to 40-50℃ and 70-80% humidity and cure it for 12-16 hours. Finally, cool it down to room temperature and cure it naturally for 24-36 hours. Demold the mold to obtain the concrete aerogel composite insulation wall panel.

[0023] In S1, the modifier solution is a mixed solution prepared by silane coupling agent KH-550 and ethanol at a volume ratio of 1:15-20. The liquid-solid ratio of the modifier solution to the nano silica aerogel particles is 5-8:1. In S2, the vacuum degree of vacuum degassing is -0.08~-0.1MPa, the degassing time is 15-20 minutes, and the thickness of the aerogel insulation core layer is controlled at 20-40mm.

[0024] In S3, the aggregate is a mixture of quartz sand with a particle size of 0.5-1mm and basalt crushed stone with a particle size of 2-5mm at a mass ratio of 2:1. The admixture is a polycarboxylate-based high-efficiency water-reducing agent. In S4, the mesh size of the glass fiber mesh is 80-120 mesh, and the adhesion between the mesh and the concrete slurry during laying is not less than 95%. The vibration compaction frequency is 50-60Hz, and the compaction time is 3-5 minutes. In S4, the cavity size error of the composite mold is controlled within ±0.5mm. The thickness of the bottom layer of concrete slurry is 30-50mm, and the thickness of the top layer of concrete slurry is the same as that of the bottom layer. In S5, the heating rate is controlled at 5-8℃ / hour, and the cooling rate is controlled at 3-5℃ / hour to avoid cracking of the wall panel due to sudden temperature changes.

[0025] It also includes post-processing steps: sanding the surface of the demolded wall panel to remove burrs and protrusions, then spraying a layer of penetrating waterproofing agent on the surface at a rate of 0.2-0.3 kg / m², and storing it in the warehouse after it has dried naturally.

[0026] In S2, the curing agent is an amine-based curing agent. After the aerogel insulation core layer is cured, its compressive strength is tested. The passing standard for the test is a compressive strength ≥ 1.5 MPa. In S3, the concrete slurry is mixed using a twin-shaft screw mixer. The mixing time is 8-12 minutes, and the mixing speed is 300-400 r / min to ensure that the slurry is uniform and free of lumps.

[0027] Principle: Aerogel particles are modified with silane coupling agent KH-550 to improve their compatibility with epoxy resin and prevent aerogel agglomeration; vacuum degassing process removes air bubbles from the insulation core layer to ensure its density; during composite molding, glass fiber mesh serves as a reinforcing transition layer to strengthen the bond between the concrete substrate layer and the aerogel insulation core layer; gradient curing process reduces wall panel cracking caused by temperature stress through slow heating and cooling; efficient mixing by a twin-shaft screw mixer ensures the uniformity of the concrete slurry, ultimately achieving a synergistic improvement in the insulation performance and mechanical strength of the wall panel.

[0028] The above description is merely a preferred embodiment of the present invention; however, the scope of protection of the present invention is not limited thereto; any equivalent substitutions or modifications made by those skilled in the art within the technical scope disclosed in the present invention, based on the technical solution and its improved concept, should be covered within the scope of protection of the present invention.

Claims

1. A method of producing a concrete aerogel composite thermal wall panel, characterized by: It comprises the following steps: S1, put the nano-silica aerogel particles into the modifier solution, stir and disperse at 30-40℃ for 20-30 minutes, filter and dry at 80-100℃ to constant weight to obtain modified aerogel; S2, mix the modified aerogel, epoxy resin and curing agent according to the mass ratio of 1:3-5:0.8-1.2, pour into the mold, vacuum degassing, and then cure at 50-60℃ for 2-3 hours to form the aerogel insulation core layer (4); S3, mix cement, aggregate, additive and water according to the mass ratio of 1:2.5-3.5:0.02-0.05:0.4-0.5, stir evenly to obtain the concrete slurry (2); S4, first pour the concrete slurry (2) into the bottom layer of the composite mold (1), lay a layer of glass fiber mesh cloth (3), then embed the cured aerogel insulation core layer (4) in the middle of the composite mold (1), and then pour the concrete slurry (2) into the upper layer of the composite mold (1), and then vibrate and compact, and then smooth the surface; S5, put the composite mold (1) into the curing room, first cure at 20-25℃ and 80-90% humidity for 4-6 hours, then heat to 40-50℃ and 70-80% humidity for 12-16 hours, and finally cool to room temperature for natural curing for 24-36 hours, and then demold to obtain the concrete aerogel composite insulation wallboard.

2. The method of claim 1, wherein the method further comprises: The modifier solution in S1 is a mixed solution prepared by mixing silane coupling agent KH-550 and ethanol according to the volume ratio of 1:15-20, and the liquid-solid ratio of the modifier solution to the nano-silica aerogel particles is 5-8:

1. ​ 3. The method of claim 1, wherein the method further comprises: The vacuum degree of vacuum degassing in S2 is-0.08~-0.1MPa, the degassing time is 15-20 minutes, and the thickness of the aerogel insulation core layer (4) is controlled within 20-40mm. ​ 4. The method of claim 1, wherein the method further comprises: The aggregate in S3 is prepared by mixing quartz sand with a particle size of 0.5-1mm and basalt gravel with a particle size of 2-5mm according to the mass ratio of 2:1, and the additive is a polycarboxylic acid high-efficiency water reducing agent. ​ 5. The method of claim 1, wherein the method further comprises: The mesh number of the glass fiber mesh cloth (3) in S4 is 80-120, the adhesion degree with the concrete slurry is not less than 95% during laying, the vibration compaction frequency is 50-60Hz, and the compaction time is 3-5 minutes. ​ 6. The method of claim 1, wherein the method further comprises: The cavity size error of the composite mold (1) in S4 is controlled within ±0.5mm, the thickness of the bottom layer of the concrete slurry is 30-50mm, and the thickness of the upper layer of the concrete slurry is the same as that of the bottom layer. ​ 7. The method of claim 1, wherein the method further comprises: The heating rate in S5 is controlled within 5-8℃ / hour, and the cooling rate is controlled within 3-5℃ / hour, so as to avoid wallboard cracking caused by sudden temperature change. ​ 8. The method of claim 1, wherein the method further comprises: It further comprises a post-treatment step of the finished product: polishing the surface of the demolded wallboard to remove burrs and protrusions, then spraying a layer of permeable waterproof agent on the surface, the spraying amount is 0.2-0.3kg / ㎡, and then naturally air-drying before storage. ​ 9. The method of claim 1, wherein the method further comprises: The curing agent in S2 is an amine curing agent, and the aerogel insulation core layer (4) is subjected to compression strength detection after curing, and the detection qualified standard is that the compression strength is ≥1.5MPa. ​ 10. The method of claim 1, wherein the method further comprises: The concrete slurry in the S3 is stirred by a double-shaft spiral stirrer, the stirring time is 8-12 minutes, and the stirring speed is 300-400 r / min, so that the slurry is uniform and free of lump. ​

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